Carrier 48HJ015-025 User's Manual
Contents
1. ae g CSN LL CL SN N FLUE ZA GOD o lo o COMBUSTION L C L FAN HOUSING S55 S55 INSIDE SS _ lo o fef e E Fig 9 Flue Hood Location PRESSURE SWITCH COMBUSTION FAN HOUSING HEAT EXCHANGER SECTION vei Fig 10 Combustion Fan Housing Location Step 6 Trap Condensate Drain See Fig 11 for drain location One 4 in half coupling is provided inside unit evaporator section for condensate drain connec tion An 8 in x in diameter and 2 in x in diameter pipe nipple coupled to standard 3 in diameter elbows pro vides a straight path down through hole in unit base rail see Fig 12 A trap at least 4 in deep must be used Step 7 Install Gas Piping Unit is equipped for use with natural gas Installation must conform with local building codes or in the absence of local codes with the National Fuel Gas Code ANSI Z223 1 Install manual gas shutoff valve with a s in NPT pres sure tap for test gage connection at unit Field gas piping must include sediment trap and union See Fig 13 A WARNING Do not pressure test gas supply while connected to unit Always disconnect union before servicing Natural gas pressure at unit gas connection must not be less than 5 in wg or gr2. TYP 4 PLCS 9317 2D 0 te Bi 2121 1 7 13 167 1 4 5 161 4 9 167 e pr 0 5 IS 16 07 8 1 84 REAR E 504 GI Zr 4239 E asn 206 ace H m 07 4 5 16 73 4009 Mot rm n zu 3 B 15 165 786 I 1 l 2 1 S 8 651 1 RETURN S 11 7 8 1 6 5 16 49 318 OUTDOOR 1 AIR te de 1825 i i iy 202 SECTION i CL ash cd i 7 2 8 Gop 1 6 S 16 1 2187 466 i VIEW Z Z 1 POWER EXHAUST BAROMETRIC RELIEF i ACCESSORY ONLY l POWER EXHAUST BAROMETRIC RELIEF 1 ACCESSORY ONLY PUN 0 10 13716 1 87 274 3 id MAXIMUM SHIPPING WEIGHT 3 3h r FRONT Lb Kg i0 7 A ais ith 2 DIA K O NEN o DLA DOLE 2535 1150 50 12 ke0 11 15716 303 CORNER B CORNER C 3 amp 1 3 8 DIA CONCENTRIC K O 76 35 UE e 0 2 1 4 557 25 AIR OR 57 AR SIDE 1 10 5715 e ECONOMIZER HCO 0 3 76 1 1 5 16 _ 0 4 339 DIE 102 LEFT ioe 3 8 1 4 0 3 7 16 2 1124 4 gy SECTION A A S RIGHT j 5 NOTES lt Senti 18 1 6 378 1 Dimensions in are in millimeters 508 i meo 2 D Center of gravity o 3 3 O gt Direction of airflow 76 A n INDOOR COIL prm ACT RMATE RETURN 4 Ductwork to be attached to accessory roof curb only 3 4 FPT DRAIN CONNECTION 5 Minimum clearance Ju 27 FAR SIDE ONLY a Rear 7 0 2134 for coil removal This dimen sion can be reduced to 4 0 1219 if conditions 0 A 4 m permit coil
3. 43 NOM S 4 x 47 G2 X 102 TYP 4 PLCS 0 1 3 47 44 27 50PQ900151 AND 50DP900211 ONLY 0 6 1 i 1886 INSULATED PANEL FOR SIDE SUPPLY AND RETURN 50PQ900151 AND 50DP900211 ONLY U 0 1 1 4 G2 HEIGHT FROM TABLE rt r UNIT OPENINGS 1 7 rg 504 ae 1 4 5 16 415 1 4 9 16 20 OPTIONAL 7 RETURN SUPPLY RETURN E pm t SUPPLY AIR ns SECTION A A OPTIONAL SIOE SUPPLY GASKET SUPPLIED WITH CURB er Ec vy em sea fi Kd COUNTER FLASHING N FIELD SUPPLIED NS ROOF ING FELT DUCT FIELD SUPPLIED Apos E comPR SUPRET RETURN Min SROOF ING MATERIAL SECT OPENING OPENING FIELD SUPPLIED CURB CURB 5 9 A A 1753 E E E T i Tp ee d dom Pp Le EE AND GAS ENTRY F Aade le ee Pe Si B 935 3716 17 0 al r 305 17 1 18 164 349 UAM Cen k 1 37167 310 ATTACH DUCT TO ROOF CURB ACCESSORY CURB pr PACKAGE NO HEIGHT DESCRIPTION ESES e 1 2 Standard Curb sopasoo221 aos seg Standard Curb for Units Requiring High Installation 50PQ900141 Horizontal Supply 0 2 1 6 50PQ900151 and Return Curb 64 457 Pre Assembled 0 6 A 1 254 High Static Horizontal Adapter 159 371 50DP90021
4. 16 OPTIONAL FACTORY INSTALLED ECONOMIZER Economizer Motor Control Module See Fig 17 19 Set economizer motor to the D setting Fig 18 Damper Vent Position Setting 1 Set fan switch at ON position continuous fan operation and close night switch if used 2 Set system selector switch at OFF position 3 Turn damper adjustment knob located on control module clockwise slowly until dampers assume desired vent po sition Do not manually operate economizer motor Dam age to motor will result NOTE Refer to accessory installation instructions included with the field installed economizer for installation informa tion Also see Accessory Field Installed Economizer Adjust ment section on page 12 Step 10 Install Outdoor Air Hood The outdoor air hood is common to 25 air ventilation and economizer If economizer is used all electrical connections have been made and adjusted at the factory Assemble and install hood in the field NOTE The hood top cover upper and lower filter retain ers hood drain pan baffle 017 and 025 only and filter sup port bracket are secured opposite the condenser end of the unit The screens hood side panels remaining section of fil ter support bracket seal strip and hardware are in a package located inside the return air filter access panel Fig 20 1 Attach seal strip to upper filter retainer See Fig 21 2 Assemble hood top cover side panels upper filter re tain
5. NET ECONOMIZER CONTROL MODULE Fig 19 Economizer Motor Control Module Location OUTDOOR AIR HOOD AND MOUNTING BRACKETS ug aS PACKAGE AND RETURN AIR FILTER ACCESS PANEL COMPONENTS Fig 20 Outdoor Air hs Component Location HOOD TOP PANEL HOOD DRAIN PAN UPPER FILTER RETAINER ET SEAL STRIP Fig 21 Seal Strip Location HOOD SIDE PANELS 2 HOOD TOP TANGE BAFFLE 017 025 ONLY LOWER FILTER RETAINER FILTER SUPPORT BRACKET HOOD DRAIN PAN UPPER FILTER RETAINER Fig 22 Outdoor Air Hood Details START UP Use the following information and Start Up Checklist on page CL 1 to check out unit PRIOR to start up Unit Preparation Check that unit has been installed in accordance with these installation instructions and appli cable codes Compressor Mounting Loosen the compressor hold down bolts until sidewise movement of the washer under each holddown bolt head can be obtained Do not loosen completely as bolts are self locking and will maintain adjustment Internal Wiring Check all electrical connections in unit control boxes tighten as required Refrigerant Service Ports and Valves Each 48HJ unit has 2 Schrader type service ports per circuit one on the suction line and one on the liquid line Be sure that the caps on the ports are tight The units also have 2 service valves per circuit one on the suction line and one on the discharge lin
6. 7 5 2 5700 3 5 4 0 4 5 5 0 5 5 6000 3 8 4 3 4 8 5 3 5 8 6300 4 1 4 6 5 1 5 6 6 1 6400 4 4 4 9 5 4 5 6 6 5 6900 4 8 5 2 5 7 6 3 6 8 7200 5 1 5 6 6 1 6 6 7 2 7500 5 5 6 0 6 5 7 1 7 5 LEGEND 5 Static pressure osses e aconom zer must be added exer nal static pressure before entering Fan Performance table See Bhp Brake Horsepower Input to Fan Table 7 for accessory FIOP static pressure information FIOP Factory Installed Option 6 Interpolation i issible D text lat Watts Input Watts to Motor polation is permissible Do not extrapolate 7 Maximum continuous bhp is 5 9 and the maximum continuous watts NOTES n are 5180 Extensive motor and drive testing on these units en 1 Boldface indicates standard operating range sures that the full horsepower range of the motor can be utilized T i with confidence Using your fan motors up to the watts rating shown 2 E indicates field supplied motor and drive required will not result in nuisance tripping or premature motor failure Unit 3 All other numbers indicate field supplied drive required warranty will not be affected 4 Factory shipped motor drive range is 1238 to 1494 rpm Other rpms require a field supplied drive 15 Table 5 Fan Performance Data 48HJ025 Units EXTERNAL STATIC PRESSURE in wg 1 0 ENERO RNEENUINENENED DENS eee NRENENE e Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp EXTERNA
7. Fan Performance table See FIOP Panier O haa pee Table 7 for accessory FIOP static pressure information Watts Input Watts to Maior 6 Interpolation is permissible Do not extrapolate p 7 Maximum continuous bhp is 3 45 and the maximum continuous NOTES n watts are 3065 Extensive motor and drive testing on these units 1 Boldface indicates standard operating range ensures that the full horsepower range of the motor can be uti ds lized with confidence Using your fan motors up to the watts rating 2 indicates field supplied motor and drive required shown will not result in nuisance tripping or premature motor fail 3 All other numbers indicate field supplied drive required ure Unit warranty will not be affected 4 Factory shipped motor drive range is 1201 to 1462 rpm Other rpms require a field supplied drive 14 Table 4 Fan Performance Data 48HJ017 Units EXTERNAL STATIC PRESSURE in wg n 9m p 34 d o c c8 c 70 5 908 1 CFM Fam was Bhp Rpm Wats Eng Fem Watts Bhp mpm watts Bip Fem wes Bhp 4500 0 9 1 2 1 5 1 9 2 2 4800 1 1 1 4 1 7 2 0 2 4 5100 1 2 1 5 1 9 2 2 2 6 5400 1 4 1 7 2 1 24 2 8 5700 1 6 2 0 2 3 2 7 3 1 6000 1 8 2 2 2 6 2 9 3 4 6300 2 1 2 5 2 8 3 2 3 6 6600 2 4 2 7 3 1 3 5 4 0 6900 2 6 3 0 3 4 3 9 4 3 7200 2 9 3 4 3 8 4 2 4 6 7500 3 3 3 7 4 1 4 6 5 0 AIRFLOW CFM Bhp 4500 2 6 3 1 3 5 4 0 4 4 4800 2 8 3 8 3 7 4 2 4 7 5100 3 0 3 5 4 0 4 4 4 9 5400 3 3 3 7 4 2 4
8. Light If pilots do not light as described in Gas Heat section on page 17 be sure that pilot orifice is not ob structed then check for spark ignitor malfunctions as fol lows 1 Shutoff control supply power to ignitor control pack ICP 2 Check that spark gap is Vs in 1 2 inch 3 Check that ICP is securely grounded 4 Check that high voltage lead is securely connected be tween ICP and electrode body 5 Restore power to ICP Check that 24 v is supplied tror ICP 6 Check unit label diagram for correct terminal usage if any wires are removed to terminal OUTDOOR TEMP Frog H 125 52 115 46 105 41 95 35 85 29 620 90 551 80 75 24 483 414 345 SUCTION LINE PRESSURE KILOPASCALS SUCTION LINE PRESSURE PSIG 276 207 20 30 40 50 60 70 80 SUCTION LINE TEMPERATURE F 1 4 10 16 21 27 SUCTION LINE TEMPERATURE C Fig 33 Cooling Charging Chart 48HJ015 OUTDOOR TEMP Fe ce 620 890 125 52 115 46 Li nos 41 F7 95 35 85 29 e e eo a En Es n am
9. Motor Adjustment SERVICE AND REPLACEMENT See Fig 30 The 48HJ017 025 units use a fan motor mounting system that features a slide out motor mounting plate To replace or serv ice the motor slide out the bracket Remove the evaporator fan access panel and the heat ing control access panel 2 Remove the center post located between the evaporator fan and heating control access panels and all screws securing it 3 Loosen nuts on the two carriage bolts in the motor mount ing base 4 Using jacking bolt under motor base raise motor to top of slide and remove belt Secure motor in this position by tightening the nuts on the carriage bolts 5 Remove the belt drive 6 Remove jacking bolt and tapped jacking bolt plate 7 Remove the 2 screws that secure the motor mounting plate to the motor support channel 8 Remove the 3 screws from the end of the motor support channel that interfere with the motor slide path 9 Slide out the motor and motor mounting plate 10 Disconnect wiring connections and remove the 4 mount ing bolts 11 Remove the motor 12 To install the new motor reverse Steps 1 11 Belt Tension Adjustment To adjust belt tension 1 Loosen fan motor bolts 2 a 015 Units Move motor mounting plate up or down for proper belt tension 2 in deflection with one finger b 017 025 Units Turn motor jacking bolt to move mo tor mounting plate up or down for proper belt tension in defl
10. S716 tb oR Le SECTION A A i 87 RIGHT SIDE Q 1023 ALTERNATE RETURN 3 4 FPT DRAIN CONNECTION FAR SIDE ONLY WEIGHT OF CORNER a S A A A EL i5 Ks te Ks tb Ks 1b Weights are for unit only and do not include options or crating NOTES 1 Dimensions in are in millimeters 2 e Center of gravity Direction of airflow Ductwork to be attached to accessory roof curb only Minimum clearance a Rear 7 0 2134 for coil removal This dimension can be reduced af Lors to 4 0 1219 if conditions permit coil removal from the top 76 b Left side 4 0 1219 for proper condenser coil airflow 1 1 4 DIA HOLE c Front 4 0 1219 for control box access aa d Right side 4 0 1219 for proper operation of damper and power exhaust if so equipped e Top 6 0 1829 to assure proper condenser fan operation f Local codes or jurisdiction may prevail 6 With the exception of clearance for the condenser coil and the damper power exhaust as stated in Note No 5 a removable fence or barri cade requires no clearance 7 Dimensions are from outside of corner post Allow 0 5Ae 8 on each side for top cover drip edge Fig 4 Base Unit Dimensions 48HJ015 017 CORNER 0 1 3 8 DIA DRAIN HOLE CORNER A
11. SUPPLY VOLTAGE L1 L2 L2 L3 L3 L1 COMPRESSOR AMPS COMPRESSOR NO 1 L1 L2 L3 COMPRESSOR NO 2 L1 L2 L3 SUPPLY FAN AMPS EXHAUST FAN AMPS TEMPERATURES OUTDOOR AIR TEMPERATURE F DB Dry Bulb RETURN AIR TEMPERATURE F DB F WB Wet Bulb COOLING SUPPLY AIR F GAS HEAT SUPPLY AIR F PRESSURES GAS INLET PRESSURE IN WG GAS MANIFOLD PRESSURE STAGE NO 1 IN WG STAGE NO 2 IN WG REFRIGERANT SUCTION CIRCUIT NO 1 PSIG CIRCUIT NO 2 PSIG REFRIGERANT DISCHARGE CIRCUIT NO 1 PSIG CIRCUIT NO 2 PSIG VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS ON PAGES 21 AND 22 GENERAL ECONOMIZER MINIMUM VENT AND CHANGEOVER SETTINGS TO JOB REQUIREMENTS Copyright 1995 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 PC 111 Catalog No 534 807 Printed in U S A Form 48Hu 9SI Pg CL 1 2 95 Replaces 48HJ 5SI Tab ia CUT ALONG DOTTED LINE
12. building When unit is located adjacent to public walkways flue assembly must be at least 7 ft above grade ROOF MOUNT Check building codes for weight distri bution requirements Unit weight is shown in Table 1 Instructions continued on page 7 DETAIL A RIGGING HOOK jo UNIT BASE RAIL Dimensions in are in millimeters Refer to Table 1 for unit operating weights Remove boards at ends of unit and runners prior to rigging Rig by inserting hooks into unit base rails as shown Use corner post from packaging to protect coil from damage Use bumper boards for spreader bars Weights do not include optional economizer See Table 1 for econo mizer weight Weights given are for aluminum evaporator coil plate fins and cop per condenser coil plate fins Weights of other metal combinations are listed in Table 1 A CAUTION All panels must be in place when rigging Fig 3 Rigging Details Table 1 Physical Data HJD015 HJE015 Piae 208 230 A60 V uitis OPERATING WT Ib AI AI 1640 1660 2235 Unit Al Cu 1770 1790 2385 Cu Cu 1840 1860 2515 Economizer 110 110 Roof Curbt 200 200 COMPRESSOR 06D Semi Hermetic Number 1 2 2 Cylinders 6 4 6 REFRIGERANT TYPE R 22 Charge Ib System 1 22 50 14 25 17 50 System 2 15 00 17 00 CONDENSER COIL Copper Tubes Aluminum or Copper Plate Fins Rows 3 4 4 Fins in 15 15 15 Total Face Area sq ft 22 2 22 2 22 2 CONDENSER FAN Propeller Type Dir
13. 025 or unloaded compressor 015 and condenser fan start The condenser fan motors run continuously while unit is cooling If the ther mostat calls for a second stage of cooling by energizing Y2 compressor contactor no 2 C2 is energized and compres sor no 2 starts 017 025 or compressor no 1 runs fully loaded 015 A freeze protection thermostat FPT is located on the evaporator coil It detects frost build up and locks out the compressors allowing the coil to clear Once frost has melted the compressors can be reenergized by resetting the thermostat HEATING UNITS WITHOUT ECONOMIZER NOTE The 48HJDO15 units have 1 stage of heat and the 48HJE015 48HJE017 and HJD025 units have 2 stages of heat First Stage Turn unit power on Open manual gas line valve Set thermostat system switch at HEAT or AUTO po sition and set fan switch to AUTO position for heating First stage thermostat calls for heat Time delay relay for evaporator fan begins timer sequence Induced draft relay closes and induced draft motor starts 17 ECONOMIZER PRESSURE DROP 6 000 07 7 200 09 9 000 11 10 000 12 2 The static pressure must be added to external static pressure The sum and the evaporator entering air cfm should then be used in conjunction with the Fan Performance table to determine blower rpm bhp and watts Pressure switch closes and pilot valve no opens allow ing gas to flow to the first stage pilot Spark
14. 1 LEGEND COMP SECT Compressor Section NOTES Roof curb accessory is shipped unassembled Insulated panels 1 2 in thick neoprene coated 2 Ib density Dimensions in are in millimeters E Direction of airflow Roof curb 18 gage steel Attach all ductwork to roof curb Field installation of sidewall is mandatory Noo R wna CONDENSER PRESSOR PRE con END 28 DEG 45 IN i CONDENSATE CONDENSER DRAIN AND COMPRESSOR 28 DEG END 43 IN NOTE To prevent the hazard of stagnant water build up in the drain pan of the indoor air section unit can only be pitched as shown Fig 1 Roof Curb and Horizontal Adapter Details EVAPORATOR FAN MOTOR 48HJ015 EVAPORATOR FAN MOTOR 48HJ017 025 25 VENT AIR ECONOMIZER HOOD AIR IN BLOCKOFF PAN HORIZONTAL SUPPLY CURB FACTORY SUPPLIED HIGH STATIC 50PQ900151 OR 50DP900211 REGAIN TRANSITION DUCT 50DP900211 FIELD SUPPLIED TRANSITION DUCT 50PQ900151 Fig 2 Horizontal Supply Return Curb and Horizontal Adapter Details ALTERNATE UNIT SUPPORT When the curb cannot be used install unit on a noncombustible surface Support unit with sleepers using unit curb support area If sleepers cannot be used support long sides of unit with a minimum of 3 equally spaced 4 in x 4 in pads on each side Step 2 Rig and Place Unit Inspect unit for trans portation damage File any claim with transportation agenc
15. 25 Refer to Main Burners section on page 23 for burner removal sequence If cleaning is re quired remove heat exchanger turbulators Fig 26 and clean all parts with a wire brush COMBUSTION AIR BLOWER Clean periodically to as sure proper airflow and heating efficiency Inspect blower wheel every fall and periodically during heating season For the first heating season inspect blower wheel bi monthly to determine proper cleaning frequency To inspect blower wheel remove heat exchanger access panel Shine a flashlight into opening to inspect wheel If cleaning is required remove motor and wheel assembly by removing screws holding motor mounting plate to top of com bustion fan housing Fig 25 and 26 The motor and wheel assembly will slide up and out of the fan housing Remove the blower wheel from the motor shaft and clean with a de tergent or solvent Replace motor and wheel assembly EVAPORATOR COIL Clean as required with commer cial coil cleaner CONDENSER COIL Clean condenser coil annually and as required by location and outdoor air conditions Inspect coil monthly clean as required CONDENSATE DRAIN Check and clean each year at start of cooling season In winter keep drains and traps dry FILTERS Clean or replace at start of each heating and cooling season or more often if operating conditions re quire Refer to Table 1 for type and size OUTDOOR AIR INLET SCREENS Clean screens with steam
16. 4000 4500 CFM Fig 24 Fan Performance Using Accessory Power Exhaust 5000 Table 7 Accessory FIOP Economizer Static Pressure in wg UNIT UNIT 480HJ VOLTAGE 015 017 All 025 LEGEND BHP Brake Horsepower FIOP Factory Installed Option NOTES 1 The factory assembled horizontal adapter substantially improves fan performance See Fig 24 Gas Heat Verify gas pressures before turning on heat as follows 1 Turn off manual gas stop 2 Connect pressure gage to supply gas tap See Fig 13 on page 8 3 Connect pressure gage to manifold pressure tap on gas valve 4 Turn on manual gas stop and set thermostat to HEAT po sition After the unit has run for several minutes verify that incoming pressure is 5 0 in wg or greater and that the manifold pressure is 3 5 in wg If manifold pressure must be adjusted refer to Gas Valve Adjustment section on page 22 5 After unit has been in operation for 5 minutes check tem perature rise across the heat exchangers See unit infor mative plate for correct rise limits of the heat supplied Air quantities may need to be adjusted to bring the actual rise to within the allowable limits Base Unit Operation COOLING UNITS WITHOUT ECONOMIZER When thermostat calls for cooling terminals G and Y1 are ener gized The indoor evaporator fan contactor IFC and compressor contactor no 1 C1 are energized and evaporator fan motor IFM compressor no 1 017
17. 48HJ015 025 Single Package Rooftop Units Electric Cooling Gas Heating Installation Instructions CONTENTS Page SAFETY CONSIDERATIONS 1 INSTALLATION sseeeeeeee 1 12 Step 1 Provide Unit Support 1 ROOF CURB ALTERNATE UNIT SUPPORT Step 2 Rig and Place Unit 3 POSITIONING ROOF MOUNT Step 3 Field Fabricate Ductwork 7 Step 4 Make Unit Duct Connections 7 Step 5 Install Flue Hood 7 Step 6 Trap Condensate Drain 8 Step 7 Install Gas Piping 8 Step 8 Make Electrical Connections 9 FIELD POWER SUPPLY FIELD CONTROL WIRING Step 9 Make Outdoor Air Inlet Adjustments usss esses 10 MANUAL OUTDOOR AIR DAMPER OPTIONAL FACTORY INSTALLED ECONOMIZER Step 10 Install Outdoor Air Hood 10 START UP sss eere ES par Sbhalee eek 12 17 SERVICE torem 18 27 START UP CHECKLIST CL 1 SAFETY CONSIDERATIONS Installation and servicing of air conditioning equipment can be hazardous due to system pressure and electrical com ponents Only trained and qualified service personnel should install repair or service air conditioning equipment Untrained personnel can perform the basic maintenance functions of cleaning coils and filters and replacing filters All other operations should be performed by trained s
18. L STATIC PRESSURE in wg AIRFLOW CFM 6000 6500 7000 7500 8000 8500 9000 9500 10000 AIRFLOW CFM 6000 3 80 6500 4 32 7000 4 92 7500 5 58 8000 6 33 8500 7 17 9000 8 08 9500 9 10 10000 10 20 LEGEND Bhp Brake Horsepower Input to Fan FIOP Factory Installed Option Watts Input Watts to Motor NOTES 1 2 3 4 Boldface indicates standard operating range All other numbers indicates field supplied drive required Factory shipped motor drive range is 1323 to 1579 rpm Other roms require a field supplied drive Static pressure losses i e economizer must be added to exter nal static pressure before entering Fan Performance table See Table 7 for accessory FIOP static pressure information Table 6 Air Quantity Limits UNIT 48HJ MAXIMUM CFM 015 3 750 6 250 017 7 500 025 70 000 16 5 6 STATIC PRESSURE in wg Interpolation is permissible Do not extrapolate Maximum continuous bhp is 10 2 for 208 230 and 575 v units and 11 8 for 460 v units The maximum continuous watts are 9510 for the 208 230 and 575 v units and 11 000 for the 460 v units Ex tensive motor and drive testing on these units ensures that the full horsepower range of the motor can be utilized with confidence Using your fan motors up to the watts rating shown will not result in nuisance tripping or premature motor failure Unit warranty will not be affected 0 3 o N 2 a 0 3500
19. OR PROTECTION A manual reset calibrated trip magnetic circuit breaker protects against overcurrent Do not bypass connections or increase the size of the breaker to correct trouble Determine the cause and correct it before resetting the breaker CONDENSER FAN MOTOR PROTECTION Each condenser fan motor is internally protected against overtemperature HIGH AND LOW PRESSURE SWITCHES If either switch trips or if the compressor overtemperature switch ac tivates that refrigerant circuit will be automatically locked out by the CLO To reset manually move the thermostat setting FREEZE PROTECTION THERMOSTAT FPT An FPT is located on the evaporator coil It detects frost build up and turns off the compressor allowing the coil to clear Once the frost has melted the compressor can be reenergized by resetting the CLO from the thermostat Relief Devices All units have relief devices to pro tect against damage from excessive pressures 1 e fire These devices protect the high and low side Control Circuit 24 V This control circuit is pro tected against overcurrent by a 3 2 amp circuit breaker Breaker can be reset If it trips determine cause of trouble before resetting Replacement Parts A complete list of replacement parts may be obtained from any Carrier distributor upon request 208 230 3 60 EQUIP GND ile CLO2 LK 4 TI6 9 D BLK 1H HD a BLK YEL c
20. d set thermostat set ting for no call for heat turn off main gas valve remove pressure measuring device and replace Vs in pipe plug and screw cap REGULATOR ADJUSTMENT SCREW REMOVE COVER PILOT ADJUSTMENT SCREW REMOVE COVER Fig 36 Gas Valve VIEW PRIMARY AIR FLUE BOX PORT SHUTTER COVER Me _ J g E 9 Q si 2 e MAIN BURNER SECTION Fig 37 Typical Heating Section Main Burners For most applications main burners are factory set and should require no adjustment However if burner adjustment is necessary Perform pilot adjustment 2 Turn gas valve to ON position Allow unit to operate at least 15 minutes with burner access panel in place 3 Remove access panel 4 Loosen primary air shutter Fig 37 and adjust to a mini mum opening of s inch 5 Retighten primary air shutter and reinstall access panel To check ignition of main burners and fan switch opera tion move thermostat dial above and below room tempera ture several times pausing at least one minute between cycles MAIN BURNER REMOVAL 1 Shut off field supplied manual main gas valve 2 Shut off power to unit 3 Remove unit control box gas valve access panel burner section access panel and center post Fig 4 and 5 4 Disconnect pilot ignitor and pilot proving sensor leads at ICP rollout switch leads at switch and pilot tube gas con nection s at the pilot orif
21. e Be sure all valves are open 25 VENT AIR ECONOMIZER HOOD AIR OUT rove 7 p HORIZONTAL SUPPLY HIGH STATIC REGAIN CURB 50DP900211 TRANSITION DUCT NOTES 1 Dimensions are in millimeters 2 The 50DP900211 high static regain adapter accessory may be used to provide horizontal supply return Crankcase Heater Crankcase heater is energized as long as there is power to the unit IMPORTANT Unit power must be on for 24 hours prior to start up Otherwise damage to compressor may result Evaporator Fan Fan belt and pulleys are factory in stalled See Tables 3A 3B 4 and 5 for Fan Performance Data Remove tape from fan pulley and adjust pulleys on 48HJ015 units as required See Evaporator Fan Perfor mance Adjustment section on page 19 Be sure that fans ro tate in the proper direction See Table 6 for air quantity lim its See Table 7 for static pressure drops for accessories and options See Fig 23 and 24 for fan performance using hori zontal adapter and power exhaust To alter fan performance see Performance Adjustment sections on page 19 Condenser Fans and Motors Condenser fans and motors are factory set Refer to Condenser Fan Adjustment section on page 20 as required Be sure that fans rotate in the proper direction Return Air Filters Check that correct filters are in stalled in filter tracks see Table 1 Do not operate unit with out return air filters Outdoor Air Inlet Sc
22. eater than 13 5 in wg Size gas supply piping for 0 5 in wg maximum pressure drop Do not use supply pipe smaller than unit gas connec tion 4 in NPT 3 4 FPT DRAIN 1 3 8 CONNECTION DRAIN HOLE Fig 11 Condensate Drain Details 3 4 IN FPT DRAIN CONNECTION HALF COUPLING 2 IN FIELD SUPPLIED NIPPLE BASE RAIL 8 1 2 IN FIELD SUPPLIED NIPPLE Fig 12 Condensate Drain Piping Details MANUAL SHUTOFF GAS 4 SUPPLY PRESSURE TAP 1 8 NPT PLUG TO UNIT SEDIMENT TRAP Fig 13 Field Gas Piping Step 8 Make Electrical Connections FIELD POWER SUPPLY Unit is factory wired for volt age shown on unit nameplate When installing units provide a disconnect per NEC National Electrical Code of adequate size Table 2 All field wiring must comply with NEC and local requirements Route power and ground lines through control box end panel or unit basepan see Fig 4 and 5 to connections as shown on unit wiring diagram and Fig 14 A WARNING The unit must be electrically grounded in accordance with local codes and NEC ANSI NFPA 70 National Fire Protection Association Field wiring must conform to temperature limitations for type T wire All field wiring must comply with NEC and local requirements Transformer no 1 is wired for 230 v unit If 208 230 v uni
23. ect Drive Nominal Cfm 10 500 10 500 14 200 Number Diameter in 3 22 3 22 2 30 Motor Hp 1075 Rpm Ve Ve 1 1075 Watts Input Total 1090 1090 3400 EVAPORATOR COIL Copper Tubes Aluminum or Copper Plate Fins Rows 2 3 4 Fins in 17 15 15 Total Face Area sq ft 17 9 17 9 17 9 EVAPORATOR FAN Centrifugal Adjustable Pitch Belt Drive Quantity Size in 2 10 x 10 2 10 x 10 2 12 x 12 2 12 x12 Nominal Cfm 5000 5000 6000 8000 Fan Rpm Range 1194 1526 1201 1462 1238 1494 1323 1579 Maximum Allowable Rpm 1550 Motor Pulley Pitch Diameter in 5 8 7 0 Fan Pulley Pitch Diameter in 7 9 Belt Quantity Type Length in 1 BX 51 Factory Speed Setting Rpm 1451 Motor Hp Service Factor 10 1 15 Motor Frame Size 215T FURNACE SECTION Rollout Swich cutout cae p 190 urner Orifice Diameter in drill size Natural Gas 113 33 113 33 Pilot Orifice Diameter Quantity in drill size H P Ue 1 055 54 Natural Gas 1 041 59 1 041 59 Thermostat Heat Anticipator Setting Stage 1 1 2 1 2 1 2 Stage 2 0 6 0 6 Gas Valve Quantity 1 2 2 HIGH PRESSURE SWITCH Cutout psig 426 Reset psig 320 LOW PRESSURE SWITCH Cutout psig 7 Reset psig 22 AIR INLET SCREENS Cleanable Economizer Quantity Size in Caedm x zm RETURN AIR FILTERS TYPE 10 Efficient 2 in Throwaway Fiberglass Quantity Size in Pac x a i LEGEND Al Aluminum Cu Copper Evaporator coil fin material condenser co
24. ection at midspan with one finger 9 Ib force 3 Tighten nuts 4 Adjust bolts and nut on mounting plate to secure motor in fixed position Condenser Fan Adjustment 48HJ015 017 UNITS Fig 31 1 Shut off unit power supply 2 Remove access panel s closest to the fan to be adjusted 3 Loosen fan hub setscrews 4 Adjust the fan height on the shaft using a straightedge placed across the fan orifice 5 Tighten setscrews and replace panel s 6 Turn on unit power 48HJ025 UNITS Fig 32 1 Shut off unit power supply 2 Remove fan top grille assembly and loosen fan hub screws 3 Adjust fan height on unit using a straightedge placed across the fan orifice 4 Tighten setscrews and replace rubber hubcap to prevent hub from rusting to motor shaft 5 Fill hub recess with permagum if rubber hubcap is missing Economizer Adjustment Refer to Tables 8 and 9 for economizer checkout procedures Make certain the outdoor air damper is fully closed and the return air damper is fully open before completing the following steps Turn on power to the unit 2 Turn the thermostat fan switch to the ON position The damper will go to the vent position 3 Adjust the vent position with the minimum position ad justment on the economizer motor control module See Fig 18 4 Setthe system selector switch to COOL position and set the cooling temperature selector to its lowest setting NOTE The Cooling mode may also be
25. en unit and ducts as required Insulate and weatherproof all external ductwork joints and roof openings with counter flashing and mastic in accordance with applicable codes Ducts passing through an unconditioned space must be insulated and covered with a vapor barrier Step 4 Make Unit Duct Connections Unit is shipped for through the bottom duct connections Duct work openings are shown in Fig 1 4 and 5 Duct connec tions are shown in Fig 6 Field fabricated concentric duct work may be connected as shown in Fig 7 and 8 Attach all ductwork to roof curb and roof curb basepans NOTE Do not drill in this area damage to basepan may result in water leak Fig 6 Air Distribution Through the Bottom 48HJ017 and 025 Shown AIR OUT AIR IN AIR OUT NOTE Do not drill in this area damage to basepan may result in water leak Fig 7 Concentric Duct Air Distribution 48HJ017 and 025 Shown Step 5 Install Flue Hood Flue hood is shipped secured to a baffle under main control box To install secure flue hood to access panel See Fig 9 NOTE When properly installed flue hood will line up with combustion fan housing See Fig 10 6 28 MAX 5 9 MAX 5 O s BAFFLE NOTE Dimensions A A B and B are obtained from field supplied ceiling diffuser I areas indicate block off pans Fig 8 Concentric Duct Details
26. er and drain pan see Fig 22 3 Secure lower filter retainer and long portion of support bracket to unit See Fig 22 Leave screws loose on 017 and 025 units 4 48HJ017 025 Units Only Slide baffle behind lower filter retainer and tighten screws THERMOSTAT ASSEMBLY REMOVABLE JUMPER he ul m d f Fig 15 Field Control Thermostat Wiring 25 ADJUSTABLE AIR DAMPER BASE UNIT V SECURING SCREWS Fig 16 25 Outdoor Air Section Details 5 Loosen sheet metal screws for top cover of base unit located above outdoor air inlet opening 6 Match notches in hood top cover with unit top cover screws Insert hood flange between top cover flange and unit Tighten screws 7 Insert outdoor air inlet screens and spacer in channel created by lower filter retainer and filter support bracket 8 Attach remaining shorter section of filter support bracket COOLING LOCKOUT SWITCH ECONOMIZER MOTOR ECONOMIZER MOTOR CONTROL MODULE FILTERS o OUTDOOR AIR THERMOSTAT ECONOMIZER DAMPER ASSEMBLY Fig 17 Economizer Damper Assembly End View CHANGEOVER SET POINT MINIMUM DAMPER POSITION SETTING LED LIGHTS UP TO INDICATE OUTDOOR AIR IS SUITABLE FOR FREE COOLING MINIMUM 3 LED Light Emitting Diode Fig 18 Economizer Motor Control Module 11 ECONOMIZER MOTOR O BEBE 25 65 ON Ga CI Cai bal 6s
27. ervice personnel When working on air conditioning equipment ob serve precautions in the literature tags and labels attached to the unit and other safety precautions that may apply Follow all safety codes Wear safety glasses and work gloves Use quenching cloth for unbrazing operations Have fire ex tinguishers available for all brazing operations A WARNING Before performing service or maintenance operations on unit turn off main power switch to unit Electrical shock could cause personal injury A WARNING 1 Improper installation adjustment alteration serv ice or Maintenance can cause property damage per sonal injury or loss of life Refer to the User s In formation Manual provided with this unit for more details Do not store or use gasoline or other flammable va pors and liquids in the vicinity of this or any other appliance What to do if you smell gas DO NOT try to light any appliance DONOT touch any electrical switch or use any phone in your building IMMEDIATELY call your gas supplier from a neigh bor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department A WARNING Disconnect gas piping from unit when pressure testing at pressure greater than 0 5 psig Pressures greater than 0 5 psig will cause gas valve damage resulting in haz ardous condition If gas valve is subjected to pressure greater than 0 5 psig it mus
28. ia Table 7 for accessory FIOP static pressure information Watts Input Watts to Motor 6 Interpolation is permissible Do not extrapolate p 7 Maximum continuous bhp is 4 25 and the maximum continuous NOTES o watts are 3775 Extensive motor and drive testing on these units 1 Boldface indicates standard operating range ensures that the full horsepower range of the motor can be uti m indicates field jid mot d dri ied lized with confidence Using your fan motors up to the watts rating Inolcates eic sSuppeo THeter and erive requireo shown will not result in nuisance tripping or premature motor fail 2 3 All other numbers indicate field supplied drive required ure Unit warranty will not be affected 4 Factory shipped motor drive range is 1194 to 1526 rpm Other rpms require a field supplied drive 13 Table 3B Fan Performance Data 48HJ015 575 V Units EXTERNAL STATIC PRESSURE in wg Aem ik 82 OM curo 8E Oe 1 0 CFM CEM Rem watis Bnp Rpm watts Bhp Rpm Watts Bhp Rpm Watts Bnp Rpm Watts Bhp 3750 1 53 4000 1 71 4250 1 91 4500 2 12 4750 2 34 5000 2 58 5250 02 2 84 5500 27 3 11 5750 54 3 40 6000 83 3 71 6250 13 4 03 AIRFLOW CFM Bhp 3750 2 82 4000 3 02 4250 3 23 4500 3 47 4750 3 71 5000 3 98 5250 5500 5750 6000 6250 LEGEND 5 Stati pressure Ssss les economizer must be added ener nal static pressure before entering
29. ice 5 Disconnect gas connection s from between gas valve s and main burners 6 Remove 2 screws securing burner assembly to base unit 7 Slide burner assembly out of unit p Filter Drier Replace whenever refrigerant system is exposed to atmosphere Protective Devices COMPRESSOR PROTECTION Overcurrent Each compressor has one manual reset cali brated trip magnetic circuit breaker Do not bypass connec tions or increase the size of the circuit breaker to correct trouble Determine the cause and correct it before resetting the breaker Overtemperature Each compressor has an internal pro tector to protect it against excessively high discharge gas temperatures Crankcase Heater Each compressor has a 125 watt crank case heater to prevent absorption of liquid refrigerant by oil 23 in the crankcase when the compressor is idle Since power for the crankcase heaters is drawn from the unit incoming power main unit power must be on for the heaters to be energized IMPORTANT After a prolonged shutdown or serv ice job energize the crankcase heaters for 24 hours before starting the compressors Compressor Lockout If any of the safeties high low pressure freeze protection thermostat compressor internal thermostat trip or if there is loss of power to the compres sors the cooling lockout CLO will lock the compressors off To reset manually move the thermostat setting EVAPORATOR FAN MOT
30. ignitor ignites pilot flame Sensor detects flame and the main gas valve no 1 opens Gas flows to main burners and first stage burners ignite Spark igniter turns off When sequence is complete time delay relay closes and evaporator fans start Second Stage On 2 stage units with an additional heat ing call the second stage thermostat closes The control re lay HR2 closes during the first stage of operation Pilot valve no 2 opens and the spark ignitor ignites pilot The sensor detects a flame and energizes main gas valve coil no 2 opening main gas valve no 2 Gas flows to the main burners and the second stage burners ignite The spark ignitor turns off When the second stage thermostat is satisfied the second stage gas valve closes When the first stage thermostat is satisfied the first stage gas valve closes The induced draft motor turns off the time delay relay is deenergized and the timer sequence begins When the sequence is complete the evaporator fan motor turns off COOLING UNITS WITH ECONOMIZER Upon a call for cooling when outdoor ambient is above the changeover control setting the economizer damper moves to VENT position The compressors and evaporator and condenser fans energize and operate as per Cooling Units Without Econo mizer section above Upon a first call for cooling when outdoor ambient is be low the changeover control setting the evaporator fan starts and the economizer is full
31. il fin material TWeight of 14 in roof curb Rollout switch is manual reset 1 3 8 DIA DRAIN HOLE CORNER D CORNER UP did PLC eap uz US gt s 11 7 13 16 e51 4 5 16 4 174 9 180 0 3 15 18 or gyig p 9 8 15 16 p 8 1 8 504 415 421 108 n asn 208 cELLU E EH 0 1 gt ies ZEIL l i C85 QUTDOOR SECTION RETURN 3 P 1 AIR 5 3 16 702 i I l l l t l l l i 1 L i I I D i i i I l l i i l t I 0 10 13 16 274 e Y OUTDOOR A o COIL 2 DIA K 0 0 57 bom GN 022 4 CORNER A 3 amp 1 3 8 DIA CONCENTRIC K 0 C60 G 015 f Top Lary stog 3 9 2143 01 ONLY il A HEAT EXCHANGER ACCESS PANEI BURNER SECTION ACCESS PANEI E zrost AND CENTER POST INDOOR COIL 27 0 45 102 a 0 2 3 amp 7 8 DIA CONCENTRIC K O 76 amp 22 FIELD POWER 3 5 8 amp 1 3 8 DIA CONCENTRIC K 0 92 amp 35 FIELD POWER ur 7 8 DIA K 0 CONTROL em j aT DIA K O GAS ENTRY 3 4 NPT d 0 2 YA sv l m M L4 8 15716 2 1 s 8 ESD f 5 1 7 8 sad a825 doD sre 5 9 466 les 1753 VIEW Z Z 7 2 1 8 POWER EXHAUST BAROMETRIC RELIEF 2187 ACCESSORY ONLY POWER EXHAUST BAROMETRIC RELIEF ACCESSORY ONLY s 7 8 DIA HOLE 0220 22 h 0 11 15 16 303 ORNER B 25X AIR OR ECONOMIZER HOOD 1 1
32. illow block type and have grease fittings The bearing opposite the motor end has an extended tube line so it can be lubricated from the motor side Lubricate the bearings twice annually Typical lubricants are given below MANUFACTURER LUBRICANT Texaco Regal AFB 2 Mobil Mobilplex EP No 1 Sunoco Prestige 42 Texaco Multifak 2 Preferred lubricant because it contains rust and oxidation inhibitors CONDENSER AND EVAPORATOR FAN MOTOR BEARINGS The condenser and evaporator fan motors have permanently sealed bearings so no field lubrication is necessary Evaporator Fan 48HJ015 Units PERFORMANCE ADJUSTMENT The 48HJ015 fan mo tor pulleys are factory set for speed shown in Table 1 To change fan speeds 1 Shut off unit power supply 2 Loosen belt by loosening fan motor mounting plate nuts 3 Loosen movable pulley flange setscrew see Fig 28 4 Screw movable flange toward fixed flange to increase speed and away from fixed flange to decrease speed Increasing fan speed increases load on motor Do not exceed maxi mum speed specified in Table 1 5 Set movable flange at nearest keyway of pulley hub and tighten setscrew To align fan and motor pulleys 1 Loosen fan pulley setscrews 2 Slide fan pulley along fan shaft 3 Make angular alignment by loosening motor from mount ing plate SERVICE AND REPLACEMENT See Fig 29 NOTE To remove belts only follow Steps 1 7 Remove filter and supply air secti
33. nstalled in Step 7 10 If the Cooling mode was simulated to operate the unit in Step 4 remove the jumper and reconnect the ther mostat wires to terminals Y1 and Y2 Table 8 Economizer Checkout Procedures TEST PROCEDURE RESULTS A Disconnect power at TR and TR1 Disconnect jumper be tween P and P1 See Fig 18 B Jumper TR to 1 C Jumper T1 to T D Disconnect outdoor air ther mostat connections from So and Factory installed 800 ohm resistor should re main connected to S and E Reconnect power to terminals TR and TR1 1 LED light emitting diode should be off 2 Motor is in closed position TEST PROCEDURE Disconnect factory installed re sistor from terminals S4 and RESULTS 1 LED light emitting diode should be on 2 Motor drives toward open TEST PROCEDURE A Reconnect factory installed 800 ohm resistor between ter RESULTS minals S and B Connect 1200 ohm checkout resistor between terminals So and C Turn set point potentiometer to position A Low outdoor air temperature test results 1 LED light emitting diode should be on 2 Motor drives toward open D Turn set point potentiometer to position D E Disconnect 1200 ohm check out resistor High outdoor air temperature test results 1 LED should be off 2 Motor drives toward closed Power Failure Dampers have a spring return In event of power failure dampers will return to f
34. ompe BLU FM Fae cor x B BLK CIH KO BLK YEL KO YEL OFM YL 1 3 A 2 4 E UU eu Bu YEL TRAN1 YEL YEL TRANI YEL BLK 0A 9 YEL C2 0U1 akce Ne YE C2 DUt m H2Y 5 amp 5 9 61 ve c BLK YEL O C2 DUi cR2 KD im aa 9 o YEL 2 C1 YEL Fu2 YEL 10M1 YEL CH2 A gue BLK YEL C2 c2 TRANI SEE NOTE 5 Fig 38 Typical Wiring Schematic 48HJ025 Shown 24 TO OTHER COMMUNICATING THERMOSTATS CARRIER COMMUNICATING TEMP MONITOR THERMOSTAT MODEL MS T O1ES LI OOcooO d oru ss COOL HEAT oo FAN RV 24 VAC LI COMMON TSR 01 RELAY PACK MAXIMUM CONTACT LOAD IS 1 AMP AT 24 V SEE NOTE 4 ON OFF TDR SEQUENCE CHART 10 2 MIN 0 j 30 SEC e90 150 SEC ao 50 SEC 3 BLACK DENOTES CLOSED CONTACTS SSS eee av ces I Th THIGH GAS HEAT ONLY P32 vo PLI 11 FACTORY ONLY MIXED AIR SENSOR Fig 38 Typical Wiring Schematic 48HJ025 Shown cont 25 2 Pere E Do ma GG 0 qOG G0 oon T ce ces O i wo Opu2 EQUIP GND BO eee ema a CB1 cB2 IFCB mi 2 BB CD 2 BD C2 Vie FIELD POWER WIRING FIELD CONTROL WIRING l MERA tol PLI R LT i DISCONNECT PER MEC 0o00 2 OOD puma 0o Bo D an us2 G u
35. on panels Remove unit top cover Remove coil guard Loosen screws A and B on both sides of motor mount assembly Loosen screw C Rotate motor mount assembly with motor attached as far as possible away from evaporator coil 7 Remove belt 8 Rotate motor mount assembly back past original posi tion toward evaporator coil 9 Remove motor mounting nuts D and E both sides 10 Lift motor up through top of unit 11 Reverse above procedure to reinstall motor 12 Check and adjust belt tension as necessary Evaporator Fan 48HJ017 025 Units PERFORMANCE ADJUSTMENT Fan motor pulleys are factory set for speed shown in Table 1 To change fan speeds 1 Shut off unit power supply BWN QN tA 19 2 Loosen nuts on the 2 carriage bolts in the mounting base Install jacking bolt and plate under motor base bolt and plate are shipped in installer s packet Using bolt and plate raise motor to top of slide and remove belt Secure motor in this position by tightening the nuts on the car riage bolts 3 Loosen movable pulley flange setscrew see Fig 28 STRAIGHTEDGE MUST BE PARALLEL WITH BELT MOVABLE FLANGE MOTOR AND FAN SHAFTS MUST BE PARALLEL SETSCREWS FIXED FLANGES SINGLE GROOVE Fig 28 Evaporator Fan Alignment and Adjustment MOTOR PULLEY UNIT TOP COVER MOTOR MOUNT ASSEMBLY FAN PULLEY Oo p DRAIN CONNECTION Fig 29 48HJ015 Evaporator Fan
36. or hot water and a mild detergent Do not use dis posable filters in place of screens Lubrication COMPRESSORS Each compressor is charged with the correct amount of oil at the factory Observe the level in the sight glass immediately after shutdown while the oil is still warm If the oil level is observed when the oil is cold the level observed may be a mixture of oil and refrigerant which is not a true indication of the oil level If oil level observed is not between the low limit and high limit levels as indi cated in Fig 27 add oil until it is in the correct range 18 IGNITOR CONTROL PACK NO 1 ICP 1 IGNITOR CONTROL PACK NO 2 ICP 2 INDUCED DRAFT PRESSURE MOTOR SWITCH COMBUSTION PRIMARY MAIN FLUE MAIN GAS MAIN GAS FAN AIR BURNER BOX VALVE VALVE HOUSING SHUTTER SECTION COVER NO 1 NO 2 Fig 25 Typical Gas Heating Section 48HJE015 48HJE017 and 48HJD025 Shown COMBUSTION FAN HOUSING IGNITOR CONTROL PACKS VIEWPORT TURBULATORS Fig 26 Typical Heating Section With Main Burners Removed 48HJE015 48HJE017 and 48HJD025 Shown COMPRESSOR SIGHT GLASS HIGH LIMIT 1 2 LOW LIMIT 1 4 NORMAL COMPRESSOR SIGHT GLASS OIL LEVEL Fig 27 Compressor Sight Glass Oil Level FAN SHAFT BEARINGS For 015 units the bearings are permanently lubricated No field lubrication is required For 017 and 025 units the bearings are of the p
37. p 2 75 24 N a Lu l less e E 483 70 65 18 4 ul E P 55 13 bi i 74 uw a 45 7 amp 414 60 L w H zZ 5 uet 5s z z 2 E 5 345 50 378 M H 276 40 r E au Hn 20 30 40 50 50 70 80 SUCTION LINE TEMPERATURE F 7 1 4 10 16 21 2 SUCTION LINE TEMPERATURE C Fig 34 Cooling Charging Chart 48HJ017 LLLI OUTDOOR TEMP rw 125 52 620 90 L EST 115 46 hose 41 L 95 35 3 sl 80 j H ase a4 8 z 8 75 24 Jg 7 x 483 70 65 19 g u 5 E 55 13 n ul 2 jg amp 414 4 60 a 7 w A zi 35 2 t z z iz e o 5 345 3 50 a 124 276 40 207 30 H Fi H 20 30 40 50 50 70 80 SUCTION LINE TEMPERATURE F 7 1 4 10 16 21 27 SUCTION LINE TEMPERATURE C Fig 35 Cooling Charging Chart 48HJ025 Pilot Adjustment 1 Set system selector switch at OFF position to shut off unit Turn off power to unit 2 Remove screw cap cover on pilot gas valve to expose adjusting screw See Fig 36 Turn valve knobs to pilot position 4 Turn on power to unit Set sy
38. ps MOCP Maximum Overcurrent Protection NEC National Electrical Code OFM Outdoor Condenser Fan Motor RLA Rated Load Amps This is the maximum size permissible smaller fuse size may be used where conditions permit NOTES In compliance with NEC requirements for multimotor and combina tion load equipment refer to NEC Articles 430 and 440 the overcurrent pro tective device for the unit shall be fuse or HACR breaker The Canadian units may be fuse or circuit breaker 2 j 3 E Use the following formula to determine the percent volt age imbalance Voltage Imbalance max voltage deviation from average voltage A i T EN EXAMPLE Supply voltage is 460 3 60 A BC AB 452 v BC 464 v AC 455 v Average Voltage 122 464 455 _ an 3 457 Determine maximum deviation from average voltage AB 457 452 5 v BC 464 457 7 v AC 457 455 22 v Maximum deviation is 7 v Determine percent voltage imbalance 7 Voltage Imbalance 100 x 457 1 53 This amount of phase imbalance is satisfactory as it is be low the maximum allowable 2 IMPORTANT If the supply voltage phase imbalance is more than 2 contact your local electric utility com pany immediately Unit failure as a result of operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components FIELD CONTROL WIRING Install a Carrier appro
39. r Optional Wiring IDM Induced Draft Motor RS Rollout Switch IDR nduced Draft Relay SN Sensor ex o Indicate Common Potential Only IFC Indoor Evaporator SW Switch Not To Represent Wiring Fan Contactor TB Terminal Block IFCB Indoor Evaporator TC Thermostat Cooling Fan Circuit Breaker TDR Time Delay Relay NOTES 5 CB must trip amps are equal to or less than 140 full load amps 1 Compressor and fan motors thermally protected 3 phase motors 6 Number s indicates the line location of used contacts A bracket protected against primary single phasing conditions If any of the original wire furnished must be replaced it must be over 2 numbers signifies a single pole double throw contact An underlined number signifies a normally closed contact A plain no 2 replaced with type 90 C wire or its equivalent 3 Jumpers are omitted when unit is equipped with economizer 7 4 Set thermostat heat anticipator s line number signifies a normally open contact The CLO locks out the compressor to prevent short cycling on com pressor overload and safety devices Before replacing CLO check these devices w f w wa VOLTAGE 48HJD015 All 48HJD025 HJE015 All HJE017 27 PACKAGED SERVICE TRAINING Our packaged service training programs provide an excellent way to increase your knowledge of the equipment discussed in this manual Product programs cover Unit Familiari
40. reens Outdoor air inlet screens must be in place before operating unit Accessory Field Installed Economizer Adjust ment Remove filter access panel Check that outdoor air damper is closed and return air damper is open Economizer operation and adjustment are described in Base Unit Operation section on page 17 and Economizer Adjustment section on page 20 08 wee 5S o7 a gE 06 z cz lt T 0 o8 0 5 m lt o 0 4 oz ge 03 2a tO 02 mw eo So 4000 5000 6000 7000 8000 9000 10 000 11 000 CFM NOTE The 50DP900211 horizontal supply return adapter accessory improves 48HJ fan performance by increasing external static pres sure by amount shown above Fig 23 Horizontal Supply Return Fan Performance With 50DP900211 High Static Regain Adapter 12 Table 3A Fan Performance Data 48HJ015 208 230 460 V Units EXTERNAL STATIC PRESSURE in wg A ee Oe 4 d 88 T 98 1 1 0 CFM CPP Rpm watis Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp 3750 1 53 4000 1 71 4250 191 4500 2 12 4750 2 34 5000 2 58 5250 2 84 5500 3 11 5750 3 40 6000 3 71 6250 4 03 AIRFLOW CFM Bhp 3750 2 82 4000 3 02 4250 3 23 4500 3 47 4750 3 71 5000 3 98 5250 5500 5750 6000 6250 LEGEND 5 SE pressure oases ien economizer must be added oe nal static pressure before entering Fan Performance table See FIOP Peston meted O SR
41. removal from the top aod PO 37 amp 7 8 DIA CONCENTRIC K O b 4 0 1219 to combustible surfaces all four sides 0 3 1 874 UBI B 221 E LELO POWER includes between units C Left side 4 0 1219 for proper condenser coil airflow d Front 4 0 1219 for control box access e Right side 4 0 1219 for proper operation of damper and power exhaust if so equipped f Top 6 0 1829 to assure proper condenser fan operation 9 Bottom 14 356 to combustible surfaces when nx not using curb SE h Control box side 3 0 914 to ungrounded sur faces non combustible vae py s i Control box side 3 6 1067 to block or concrete 108 walls or other grounded surfaces _ j Local codes or jurisdiction may prevail T 3 5 8 amp 1 3 8 DIA CONCENTRIC K O 6 With the exception of clearance for the condenser und PEEP e coil and the damper power exhaust as stated in Note 0 3 7 8 22 As 1 1 4 DIA HOLE No 5 a removable fence or barricade requires no DENSONS y OB LT DIA K O GAS ENTRY 374 NPT 32 clearance EDGE OF er 1 SP ig eus 7 Dimensions are from outside of corner post Allow EIE le 1676 0 546 8 on each side for top cover drip edge CORNER WEIGHT 523 Weights are for unit only and do not include options or crating Fig 5 Base Unit Dimensions 48HJ025 Step 3 Field Fabricate Ductwork Secure all ducts to building structure Use flexible duct connectors be twe
42. s ws on ee PLI R Fig 39 Typical Component Arrangement 48HJ025 Shown 26 LEGEND FOR FIG 38 and 39 AHA Adjustable Heat Anticipator IFM Indoor Evaporator TH Thermostat Heating BKR W AT Breaks with Amp Turns Fan Motor TRAN Transformer C Contactor Compressor IFR Indoor Evaporator CB Circuit Breaker Fan Relay lt gt Terminal Marked cc Cooling Compensator IP Internal Protector CH Crankcase Heater L Light E Terminal Unmarked CLO Compressor Lockout 8 TA Lockout Roay CLS Compressor Lockout Switch LPS Low Pressure Switch COMP Compressor Motor LS Limit Switch Terminal Block CR Control Relay MAT Mixed Air Thermostat CT Current Transformer MGV Main Gas Valve e Splice DM Damper Motor NEC National Electrical Code DU Dummy Terminal OAT Outdoor Air Thermostat lt gt Splice Marked EQUIP Equipment OFC Outdoor Condenser FPT Freeze Protection Fan Contactor LA Splice Field Supplied Thermostat OFM Outdoor Condenser i FU Fuse Fan Motor Factory Wiring GND Ground PGV Pilot Gas Valve HPS High Pressure Switch PL Plug Assembly Field Control Wiring HR Heat Relay PRI Primary HV High Voltage PS Pressure Switch Field Power Wiring l lgnitor QT Quadruple Terminal ICP lgnitor Control Pack R Relay Accessory o
43. simulated by removing the thermostat wires from terminals Y1 and Y2 and installing a jumper between terminals R and Y1 Refer to unit label diagram for terminal locations CENTER POST BELT MOTOR PULLEY SLIDING MOTOR MOTOR PLAT SEE NOTE MOTOR SUPPORT CHANNEL NOTE A3 in bolt and threaded plate are included in the installer s packet They can be added to the motor support channel below the motor mounting plate to aid in raising the motor Fig 30 48HJ017 025 Evaporator Fan Motor Section Fig 31 Condenser Fan Adjustment 48HJ015 017 SHIELD Fig 32 Condenser Fan Adjustment 48HJ025 5 Setthe outdoor air thermostat OAT located in the econo mizer section of the unit to 75 F 6 If the outdoor temperature is below 75 F the econo mizer will control the mixed air with the mixed air sen sor If the outdoor air is above 75 F place a jumper around the contacts of the OAT 7 Jumper terminal T to terminal T1 on the module see Fig 18 The economizer will go to the full open position The outdoor air damper will go to the full open posi tion and the return air damper will go to the full closed position 8 Adjust mechanical linkage if necessary for correct po sitioning If may be necessary to remove the filters to adjust the linkage 9 Remove the jumper from around the contacts of the OAT if installed in Step 6 Remove the jumper from termi nals T and T1 i
44. stem selector switch to HEAT position and set thermostat to a setting that will call for heat Pilot ignites 9 5 With a small screwdriver turn adjustment screw until flame fully engulfs sensor Flame can be observed through view port Fig 37 6 Turn off power to unit Replace cap on pilot gas valve Return valve knob s to original position 22 7 Check for proper burner operation by cycling the burn ers Wait 30 seconds between burner cycles 8 Check that all unit panels are in place before leaving unit Gas Valve Adjustment NATURAL GAS The gas valve opens and closes in re sponse to the thermostat or limit control When power is supplied to valve terminals 3 and 4 the pilot valve opens to the preset position When power is sup plied to terminals 1 and 2 the main valve opens to its preset position The regular factory setting is stamped on the valve body 3 5 in wg To adjust regulator 1 Set thermostat at setting for no call for heat 2 Turn main gas valve to OFF position 3 Remove 4 in pipe plug from manifold or gas valve pres sure tap connection Install a suitable pressure measuring device 4 Set main gas valve to ON position en Set thermostat at setting to call for heat 6 Remove screw cap covering regulator adjustment screw See Fig 36 7 Turn adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure 8 Once desired pressure is establishe
45. t be replaced before use When pressure testing field supplied gas piping at pressures of 0 5 psig or less a unit connected to such piping must be isolated by closing the manual gas valve s INSTALLATION Step 1 Provide Unit Support ROOF CURB Assemble or install accessory roof curb in accordance with instructions shipped with this accessory See Fig 1 and 2 Install insulation cant strips roofing and counter flashing as shown Ductwork can be installed to roof curb before unit is set in place Curb should be level This is nec essary to permit unit drain to function properly Unit level ing tolerance is Yio in per linear ft in any direction Refer to Accessory Roof Curb Installation Instructions for addi tional information as required When accessory roof curb is used unit may be installed on class A B or C roof covering material IMPORTANT The gasketing of the unit to the roof curb is critical for a watertight seal Install gasket with the roof curb as shown in Fig 1 Improperly applied gasket can also result in air leaks and poor unit performance Instructions continued on page 3 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 534 807 Book 1 PC 111 Tab jia Printed in U S A Form 48HJ 9SI Pg 1 2 95 Replaces 48HJ 5SI MITERED CORNERS TOP ONLY eega aa 2 4 0 1 11 16
46. t is to be run with 208 v power supply the transformer must be rewired as follows 1 Remove cap from red 208 v wire 2 Remove cap from orange 230 v spliced wire 3 Replace orange wire with red wire 4 Recap both wires E ed TBI FIELD POWER cm TEE EE WEE 12 22 ww SUPPLY Z 2 lem oe oe oe M aw Scl los la l T 1g EQUIP GND DIM LEGEND EQUIP Equipment GND Ground NEC National Electrical Code TB Terminal Board NOTE Maximum wire size for TB1 is 2 0 Fig 14 Field Power Wiring Connections IMPORTANT BE CERTAIN UNUSED WIRES ARE CAPPED Failure to do so may damage the transformers Operating voltage to compressor must be within voltage range indicated on unit nameplate On 3 phase units volt ages between phases must be balanced within 296 Table 2 Electrical Data NOMINAL COMPRESSOR mm UNIT VOLTAGE ll 48HJ esee ne nr a feet POWER COMBUSTION DISCONNECT oo eee oo etato E fo tate eet eet Po deel Eble fet ms EE RE BE zz i P lel ls beter Be ee s D RERO CECIGSCIEIZ COE Ee EE 057 36 195 0 57 mss uus sis 639 614 E ae felon rol a foal ne ESSE a 304 zs 2 or eae os f e 8 se 24 LEGEND FLA Full Load Amps HACR Heating Air Conditioning and Refrigeration IFM Indoor Evaporator Fan Motor LRA Locked Rotor Amps MCA Minimum Circuit Am
47. ully closed position until power is restored Do not manually operate damper motor Refrigerant Charge Amount of refrigerant charge is listed on unit nameplate and in Table 1 Refer to Carrier GTAC II Module 5 Charging Recovery Recycling and Rec lamation section for charging methods and procedures 21 Unit panels must be in place when unit is operating dur ing charging procedure NO CHARGE Use standard evacuating techniques After evacuating system weigh in the specified amount of refrigerant refer to Table 1 LOW CHARGE COOLING Using appropriate cooling charging chart see Fig 33 35 add refrigerant until condi tions of the chart are met Note that charging charts are dif ferent from those normally used Charts are based on charg ing units to correct superheat for various operating conditions An accurate pressure gage and temperature sensing device are required Connect temperature sensing device to service port on suction line and insulate it so that outdoor ambient temperature does not affect reading Indoor air cfm must be within normal operating range of unit TO USE COOLING CHARGING CHART Take outdoor ambient temperature and read the suction pressure gage Re fer to appropriate chart to determine correct suction tem perature If suction temperature is high add refrigerant If suction temperature is low carefully reclaim some of the charge Recheck suction pressure as charge is adjusted Pilot
48. ved accessory thermostat assembly according to installation instructions included with accessory Locate thermostat as sembly on a solid interior wall in the conditioned space to sense average temperature Route thermostat cable or equivalent single leads of col ored wire from subbase terminals through conduit in unit to low voltage connections as shown on unit label wiring dia gram and in Fig 15 NOTE For wire runs up to 50 ft use no 18 AWG Ameri can Wire Gage insulated wire 35 C minimum For 50 to 75 ft use no 16 AWG insulated wire 35 C minimum For over 75 ft use no 14 AWG insulated wire 35 C minimum All wire larger than no 18 AWG cannot be directly con nected at the thermostat and will require a junction box and splice at the thermostat Set heat anticipator settings as follows UNIT VOLTAGE UNIT W1 W2 48HJD015 48HJD025 HJE015 Settings may be changed slightly to provide a greater de gree of comfort for a particular installation Refer to Accessory Remote Control Panel instructions if required Step 9 Make Outdoor Air Inlet Adjustments MANUAL OUTDOOR AIR DAMPER All units except those equipped with a factory installed economizer have a manual outdoor air damper to provide ventilation air 10 Damper can be preset to admit up to 25 outdoor air into return air compartment To adjust loosen securing screws and move damper to desired setting then retighten screws to secure damper Fig
49. y MAXIMUM SHIPPING WEIGHT Dimension A UNIT mm 48HJD015 949 48HJE015 946 48HJE017 1035 48HJD025 1010 3 71 1105 NOTES 1 2 3 4 5 6 we 8048 ET SPREADER BARS Do not drop unit keep upright Use spreader bars over unit to prevent sling or cable damage Rollers may be used to move unit across a roof Level by using unit frame as a reference leveling tolerance is Yio in per linear ft in any direction See Fig 3 for additional information Unit oper ating weight is shown in Table 1 Four lifting holes are provided in ends of unit base rails as shown in Fig 3 Refer to rigging instructions on unit POSITIONING Maintain clearance per Fig 4 and 5 around and above unit to provide minimum distance from combus tible materials proper airflow and service access Do not install unit in an indoor location Do not locate unit air inlets near exhaust vents or other sources of con taminated air For proper unit operation adequate combus tion and ventilation air must be provided in accordance with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 American National Standards Institute Although unit is weatherproof guard against water from higher level runoff and overhangs Locate mechanical draft system flue assembly at least 4 ft from any opening through which combustion products could enter the building and at least 4 ft from any adjacent
50. y open The compressors remain off Upon a second stage call for cooling compressor no 1 017 025 or unloaded compressor 015 is energized and me chanical cooling is integrated with economizer cooling If the outdoor air temperature drops below 50 F a cooling lock out switch prevents the compressors from running When supply air temperature drops below a fixed set point the economizer damper modulates to maintain the tempera ture at the fixed set point HEATING UNITS WITH ECONOMIZER Outdoor air damper stays at VENT position while evaporator fan is operating SERVICE A WARNING Before performing service or maintenance operations on unit turn off main power switch to unit Electrical shock could cause personal injury Cleaning Inspect unit interior at beginning of each heat ing and cooling season and as operating conditions require Remove unit top panel and or side panels for access to unit interior MAIN AND PILOT BURNERS At the beginning of each heating season inspect for deterioration or blockage due to corrosion or other causes Observe the pilot and main burner flames through view port in condenser section and adjust if necessary Refer to Pilot Adjustment or Main Burners sec tions on pages 22 and 23 FLUE GAS PASSAGEWAYS The flue collector box and heat exchanger cells may be inspected by removing heat ex changer access panel Fig 4 and 5 flue box cover and main burner assembly Fig
51. zation Maintenance Installation Overview Operating Sequence A large selection of product theory and skills programs is available All programs include a video cassette and or slides and a companion booklet Use these for self teaching or to conduct full training sessions For a free Service Training Material Catalog STM call 1 800 962 9212 Ordering instructions are included Copyright 1995 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 PC 111 Catalog No 534 807 Printed in U S A Form 48HJ 9SI Pg 30 2 95 Replaces 48HJ 5SI Tab ia START UP CHECKLIST MODEL NO SERIAL NO DATE TECHNICIAN PRE START UP VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT REMOVE ALL SHIPPING HOLDDOWN BOLTS AND BRACKETS PER INSTRUCTIONS VERIFY INSTALLATION OF ECONOMIZER HOOD VERIFY INSTALLATION OF EXHAUST HOOD VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT CHECK GAS PIPING FOR LEAKS CHECK THAT INDOOR AIR FILTER IS CLEAN AND IN PLACE VERIFY THAT UNIT IS LEVEL CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING ORIFICE AND VERIFY SETSCREW IS TIGHT VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED START UP ELECTRICAL
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